CN112041415B

CN112041415B - Process for processing a hydrocarbon feedstock

Info

Publication number: CN112041415B
Application number: CN201880089517.9A
Authority: CN
Inventors: 杰拉尔德·F·斯维斯; 罗伯特·帕·米勒; 罗斯·艾伦·福尔克纳
Original assignee: Nike Krude Technology Co ltd
Current assignee: Nike Krude Technology Co ltd
Priority date: 2017-12-22
Filing date: 2018-12-21
Publication date: 2022-12-27
Anticipated expiration: 2038-12-21
Also published as: CO2020008886A2; EP3728517A1; EP3728517A4; CA3089102A1; US20190359896A1; WO2019126630A1; US10787612B2; RU2020124079A; CN112041415A; ECSP20041668A

Abstract

A method and modular apparatus for processing a hydrocarbon feedstock are disclosed. In particular, the processes and modular apparatuses disclosed herein are used to increase the amount of light ends that can be obtained from a hydrocarbon feedstock.

Description

Process for processing a hydrocarbon feedstock

Technical Field

The present invention relates to a method and a modular apparatus for processing a hydrocarbon feedstock. In particular, the processes and modular apparatuses disclosed herein are used to increase the amount of light ends that can be obtained from a hydrocarbon feedstock.

Background

Many hydrocarbon feedstocks are exceptionally high in viscosity, with an API of 10 or less. Such feedstocks are generally not transportable through pipelines and need to be transported by truck or train to refineries where the feedstock is refined into various components, including components having exceptionally low viscosities, including components having APIs of about 25 to 30 or higher.

Currently, to allow pipeline transport of high viscosity feedstocks to refineries, very high API light hydrocarbon fractions are transported from refineries to feedstock sources through dedicated pipelines. There, this component is introduced as a diluent into the high-viscosity feedstock. This results in a sufficient increase in the total API of the treated feedstock to allow its pipeline to the refinery. Once received at the refinery, the diluent so added can be extracted from the feedstock and re-delivered to the hydrocarbon feedstock source. It is apparent that the use of dedicated piping to transport only diluent from a refinery source to a source of hydrocarbon feedstock plus the recovery of diluent after the feedstock is transported to the refinery can incur significant costs. There are also environmental risk factors as the diluent conduits may be subject to leaks, fires etc. which may lead to environmental damage. Still further, there is an energy requirement in delivering the diluent to the source of the hydrocarbon feedstock and then separating the diluent again.

In view of the above, there is a continuing need for methods and apparatus that can increase the amount of light ends from a feedstock. In one case, such light fractions may be used to enhance the API of the feedstock without the need for the addition of an external diluent. Such methods and apparatus would provide significant environmental protection. For example, the need to provide a dedicated diluent conduit from the diluent source to the hydrocarbon source is eliminated, and the environmental risks associated therewith are eliminated. In addition, this would also eliminate the energy required to pump the diluent from the refinery to the source of the feedstock and then again separate the diluent from the feedstock upon return to the refinery.

Disclosure of Invention

The present invention provides a process and a modular apparatus for increasing the amount of light ends obtainable from a hydrocarbon feedstock. In one embodiment, such methods and apparatus may be used to increase the amount of light ends that may otherwise be obtained from a feedstock. In another embodiment, such methods and apparatus can be used to increase the API of a hydrocarbon feedstock by at least 5 API units without the addition of a side-draw diluent. The methods provided herein are preferably performed using a modular system that is easily transported to and assembled at a hydrocarbon source, thereby allowing processing of feedstock produced at the source in the methods described herein.

In one embodiment, the present invention provides an apparatus comprising: a distillation module adapted to distill a hydrocarbon feedstock into a liquid component and a gas component; a first transfer channel; and a plurality of condensing modules arranged sequentially along the first conveying path to define an upstream condensing module and a downstream condensing module;

wherein the gas component of the distillation module is in communication with each of the condensation modules through the first transfer channel, the apparatus further comprising:

a) A heating element for heating the feedstock in the distillation module,

b) A second transfer passage positioned to transfer hydrocarbons

i) Moving from a terminal end of the first transfer channel to one or more of the condensation modules;

ii) or from one of the downstream condensing modules to one or more upstream condensing modules;

c) An optional pump or blower for moving the hydrocarbons through the second transfer passage to one or more condensing modules;

d) Introducing means connected to the second transfer channel such that hydrocarbons conveyed in the second transfer channel can be introduced into one or more of the one or more condensing modules under conditions such that at least a portion of the hydrocarbon condensate in the one or more modules is cracked; and

e) A collection device for recovering the condensate from the one or more condensing modules.

In one embodiment, once sufficient condensate has been collected in one or more condensing modules, the hydrocarbon delivered from the second transfer passage 128 and introduced into one or more

condensing modules

122, 124, and/or 126 or introduced from a downstream condensing module (e.g., 126) into one or more upstream condensing modules (e.g., 122 and/or 124) is first converted to a liquid state prior to introduction into the module by appropriate temperature and pressure.

In another embodiment, the hydrocarbon transported as above (e.g., as the hydrocarbon moves from the first transfer passage 114 to the second transfer passage 128) is initially in a gaseous state and liquefies in the second transfer passage 128. The introduction of these hydrocarbons is carried out under the following conditions: wherein at least a portion of the hydrocarbons in the condensate are cracked into smaller components. Preferably, the hydrocarbons so introduced from the second transfer passage 128 are heated and injected under pressure or otherwise allowing the introduction of hydrocarbons at high velocity. Without being limited by theory, it is believed that this introduction will crack a portion of the hydrocarbons in the condensate. Moreover, since injected hydrocarbons contain volatile compounds, these compounds will vaporize rapidly once introduced into the liquid condensate. This in turn will allow those low boiling components (containing cracked molecules) in the liquid condensate to co-vaporize and transfer the resulting vapor into the gas stream in the first transfer channel 114. In a preferred embodiment, the hydrocarbons are introduced into the condensing module using a nozzle in the inlet fixture 130 mounted on the condensing module. This process allows for repeated circulation of hydrocarbons through such condensing modules to allow for significant levels of cracking to be achieved. This in turn increases the amount of light ends obtainable from the feedstock up to and even beyond the theoretical limit of recovery by distillation alone.

In another embodiment, the liquid hydrocarbon in the second transfer passage 128 is heated prior to injection, wherein the heating may be performed inside or outside the passage. Examples of heating elements include any heating device, such as, but not limited to, a microwave oven, a heating device (e.g., an electric heater), a heat exchanger, or exposing the second transfer channel to hot exhaust gases.

In yet another embodiment, the hydrocarbon introduced into the condensing module through the second transfer channel 128 is in its vapor phase and is injected into the liquid condensate of the upstream condensing module. In such embodiments, the vapor is preferably heated or superheated to promote cracking of the liquid condensate.

In one embodiment, the second transfer passage 128 has a valve 162 that is independently opened and closed for each of the condensing modules to control the flow of hydrocarbons out of or into one or more of the condensing modules. In one embodiment, a further valve 160 is provided which opens and closes at the distal end of the second transfer module. When open, all or a portion of the hydrocarbons in the second transfer passage may be directed into the third transfer passage 142. In one embodiment, the third transfer passage 142 is equipped with a blower and/or heating/pressurizing assembly (not shown) that maintains the hydrocarbons in a liquid state or converts gaseous hydrocarbons to a liquid state. These liquefied components may be recycled to the distillation module 100 for injection into the hydrocarbon feedstock 106, optionally in an injection mode, and/or used as a fuel source to generate the heat required by the distillation module.

In one embodiment, a pressure valve 110 is provided that controls the absolute gas pressure within the distillation module. The gas pressure valve may be operated visually, mechanically or automatically. This valve opens and closes to maintain the desired pressure within the distillation module 100 while releasing the hydrocarbon vapor into the first transfer passage 114.

The apparatus defined herein optionally contains an outlet port 150 to release low molecular weight hydrocarbons, such as methane, ethane, propane, butane, and the like, from the first transfer channel 114. In one embodiment, the outlet port 150 is preferably attached to the distal end of the first transfer channel 114 in a manner that releases low molecular hydrocarbon vapors such as methane, ethane, and the like. These hydrocarbons can then be collected, optionally liquefied, and used as a fuel source.

In one embodiment, the apparatus described herein allows for the conversion of an initial hydrocarbon feedstock having a first API to a conversion feedstock having a second API at least 5 units higher than the initial feedstock without the addition of a side draw diluent.

In one embodiment, the present invention provides a method comprising:

a) Heating a hydrocarbon feedstock in distillation module 100 at a first temperature and pressure selected to vaporize at least a portion of the hydrocarbon feedstock 106 to produce a distillate vapor having a plurality of fractions in a gas cap 108, wherein the vapor is collected in the gas cap 108 of distillation module 100, and further wherein the heating is performed while optionally sparging the feedstock to reduce the boiling point of the distillate to be recovered;

b) Passing at least a portion of the hydrocarbon vapor through a first transfer passage 114 in communication with a plurality of condensation modules including a first condensation module and a last condensation module, wherein the first transfer passage 114 has a first temperature at an end proximate to the distillation module 100 and a second and lower temperature at an end distal from the last condensation module such that a portion of the hydrocarbon vapor will condense throughout most, if not all, of the first transfer passage and then collect in the condensation modules;

c) Collecting condensate from each condensing module to provide condensate separated from each other and from the initial feedstock;

d) Producing a hydrocarbon stream through a second transfer passage 128, wherein the second transfer passage 128 is capable of transferring hydrocarbons

i) From the terminal end of the first transfer channel 111 to one or more of the condensation modules;

e) Introducing the hydrocarbons from the second transfer channel 128 into one or more of the condensation modules under conditions in which at least a portion of the hydrocarbon condensate in the modules is cracked; and

f) The process is continued until the desired amount of light liquid hydrocarbon fraction is recovered.

In one embodiment, the methods provided herein allow for condensate to be collected in multiple condensation modules. Without being limited by theory, the condensation process may produce a mixture of high molecular weight components and low molecular weight components. By circulating at least a portion of the hydrocarbons through the second transfer passage 128 into the one or more condensing modules coupled with cracking and volatilization, the amount of lower molecular weight components increases and will vaporize and collect in the first transfer passage. The process of the present invention allows for a significant increase in light ends over repeated cycles.

In still further embodiments, the hydrocarbons from the downstream condensing module are preferably injected into the condensate of one or more upstream modules under temperature and pressure conditions that increase the level of cracking in the liquid condensate. In such an example, this cracking increases the amount of light ends that can be obtained from the feedstock. In one embodiment, the use of a cracking catalyst is included in one or more of the condensing modules to promote hydrocarbon cracking. As can be assessed, these embodiments allow for an increase in the amount of light fraction to be collected.

The present invention provides a semi-continuous process in which additional initial feedstock is added to the distillation module 100 as vaporized feedstock is removed from the module. The process is semi-continuous in that it continues until the buildup of non-distillable components such as asphaltenes requires the process to be stopped and these components removed.

In one embodiment, after completion of the process and prior to removal, the residue remaining in the distillation module 100 is maintained within the module or other suitable vessel under conditions in which the components within the residue are substantially equilibrated to separate components that were captured in the asphaltene component prior thereto. In a preferred embodiment, one of the components separated from the asphaltene component is a diesel component.

In one embodiment, the diesel component is separated by reducing the pressure within the distillation module 100 to reduce the surface tension between the diesel component and the asphaltene component, thereby vaporizing at least a portion of the diesel component.

In one embodiment, the separation of the diesel component from the asphaltene component is facilitated by adding a distillate product having an API of 25 or greater to the distillation module.

Drawings

FIG. 1 illustrates one embodiment of the apparatus of the present invention that may be used in the apparatus and methods described herein.

Fig. 2 illustrates a variation in the first transfer channel 114 in which a plurality of bleed holes 140 are included upstream and/or downstream of the bleed member 116.

Fig. 3 illustrates one embodiment of a distillation module 100 that may be used with the apparatus and methods described herein.

FIG. 4 illustrates one embodiment of a condensation module 122 that may be used with the apparatus and methods described herein.

Fig. 5 illustrates another embodiment of the apparatus of the present invention that may be used with the apparatus and methods described herein.

Detailed Description

The present invention relates to the field of processing and separating crude oil extracts containing both light hydrocarbon fractions and heavy hydrocarbon fractions. The present invention can be used to increase the total amount of light ends that can be recovered from a hydrocarbon feedstock. This allows for the conversion of feedstocks to higher API feedstocks, particularly feedstocks suitable for pipeline transport.

Definition of

Unless defined otherwise, each technical or scientific term used herein has the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. In accordance with the appended claims and the disclosure provided herein, the following terms are defined with the following meanings, unless otherwise explicitly indicated.

The term "distillation" as used herein refers to a distillation process in which at least two or more components of a given hydrocarbon feedstock (including a plurality of components) are first vaporized. The distillation is carried out in a module or reaction vessel (distillation vessel) under conditions of temperature and pressure that provide for multiple cuts or cut hydrocarbon vapors. Preferably, the distillation is carried out under non-cracking conditions.

The term "hydrocarbon feedstock" as used herein refers to those hydrocarbon compounds and mixtures thereof that are liquid at atmospheric conditions and typically include a mixture of distillable components and non-distillable components (non-distillates) such as asphaltenes. The hydrocarbon feedstock 106 may have solids suspended therein that contain very small amounts of sulfur and other contaminants. The term "initial hydrocarbon feedstock" is encompassed by the term hydrocarbon feedstock and is used to refer to the feedstock that is fed into the distillation module 100. Once distillation begins, the initial hydrocarbon feedstock loses its properties due to partial vaporization thereof. In one embodiment, the initial hydrocarbon feedstock is obtained at a hydrocarbon source, such as an oil field, platform, or the like, and is sometimes referred to herein as a "crude oil feedstock" or "crude oil.

The term "modified hydrocarbon feedstock" refers to a feedstock that is modified by the process of the present invention (e.g., by increasing its API). In one aspect, such processes provide a modified feedstock whereby its API is increased by at least 5 API units compared to the original hydrocarbon feedstock.

The terms "component" or "fraction" as used herein refer to those hydrocarbon fractions found in crude oil feedstocks, wherein the feedstock includes a plurality of components (e.g., fractions) having art-recognized boiling points or boiling point ranges that distinguish one component from another. For example, diesel is a component of crude oil and represents a fraction boiling in the range of 180 ℃ to 360 ℃. Similarly, naphtha is a component that includes a mixture of many different hydrocarbon compounds and has an initial boiling point of about 35 ℃ and a final boiling point of about 200 ℃. The slight overlap in boiling point ranges of the components allows flexibility in the separation process. It is apparent that because crude oil feedstocks contain hydrocarbons having a wide range of molecular weights and chemical structures, there are numerous components that can be recovered as distillate. Representative components of the crude oil are as follows:

refinery gas: small molecular weight gaseous hydrocarbons such as methane, ethane, propane, and butane;

gasoline: pentane-octane;

naphtha: benzene, pentane, hexane, and cycloalkane;

gasoline/diesel oil: heptane and octane;

diesel oil: octane-undecane;

kerosene: dodecane-hexadecane;

lubricating oil;

a fuel oil; and

bitumen (bunker fuel oil).

The terms "fraction" or "component" as used interchangeably herein refer to the desired hydrocarbon component condensed and collected in the module during the process described herein.

The term "light ends" as used herein generally refers to those hydrocarbon components having an API of about 25 or greater and preferably about 30 or greater; and "heavy ends" refers to those hydrocarbon components having an API of about 25 or less.

The term "distillate" as used herein refers to compounds of the hydrocarbon feedstock that are capable of being distilled and vaporized in a distillation module according to the methods described herein.

The term "non-distillate" as used herein refers to compounds of the hydrocarbon feedstock that cannot be distilled according to the processes described herein and/or cannot be distilled in a distillation module.

The term "distillation module" refers to a module such as a reaction vessel having an input portion for feeding an initial hydrocarbon feedstock; a portion assigned to the gas cap 108; a heating device 102; a pressure control mechanism 110 that controls flow into the first transfer passage 114 in communication with the

condensation modules

122, 124, and 126, and the like. In one embodiment, the volume of the distillation module 100 may be such that it can maintain up to 2,000 barrels of feedstock 106, and preferably about 500 barrels of feedstock and corresponding gas caps 108, and more preferably up to about 300 barrels of feedstock.

The term "condensing module" refers to a module that contains its transfer conduits (e.g., 116, 118, and 120) in communication with the first transfer channel 114. Each module (e.g., 122, 124, and 126) is maintained at temperature and pressure conditions such that a portion of the hydrocarbons flowing over each module will collect as condensate in the condensing module. The portion of the hydrocarbons that are condensed depends on the temperature and pressure selected for each condensation. Such factors are within the skill of the art. Each condensation module is in communication with the first transfer channel 114. In one embodiment, one or more of the condensing modules may contain a suitable catalyst suitable for cracking as is well known in the art.

The term "gas cap" as used herein refers to the spatial volume and the general area located above the feedstock 106 in the distillation module 100. Gaseous hydrocarbons and other gases in the gas cap 108 may exit the module through an outlet valve 110. In other embodiments, an inert gas may be introduced into gas cap 106 through an inlet valve (not shown). The purpose of the gas may be, for example, to move hydrocarbon vapor together into the outlet valve and into the first transfer channel 114. Alternatively, the purpose of the gas may be to provide heat exchange to maintain a constant temperature within the gas cap.

The term "inert gas" as used herein refers to a gas that is in contact with, but does not react with, the hydrocarbon components in the module under the given conditions inside the module. For example, methane gas may be introduced into the feedstock 106 in the distillation module 100 under conditions in which the methane does not initiate cracking/hydrocracking and is therefore considered an inert gas under these conditions. Other inert gases include and are not intended to be limited to C ₂ -C ₄ Hydrocarbons, carbon dioxide, nitrogen, argon, helium, and the like.

The term "reactive gas" as used herein refers to a gas that, when introduced into the liquid component in the module under appropriate pressure and temperature conditions, contacts and reacts with liquid hydrocarbons to crack a portion of these hydrocarbons into smaller fragments. For example, in the condensing modules, the low molecular weight liquid hydrocarbons from the second transfer channel 128 may be introduced into the liquid hydrocarbon condensate in one or more condensing modules under suitable temperature and pressure conditions to interact with the liquid hydrocarbon condensate to cause cracking. Thus, by selecting the temperature and pressure used to introduce these low molecular weight hydrocarbons into the condensate, these hydrocarbons can act as inert or reactive gases. It is within the skill of the art to select such temperatures and pressures so that such gaseous low molecular weight hydrocarbons act as inert or reactive gases.

The term "sparging/sparging" as used herein refers to the introduction of an inert gas or light hydrocarbon liquid component, preferably at high velocity, into a quantity of liquid or oil, the density of the introduced gas or liquid component being lower than the density of the feedstock 106 or condensate. Without being limited by theory, light weight liquid hydrocarbons will vaporize rapidly within distillation module 100 and create bubbles that promote vaporization of higher boiling components. Because of its lower density, once introduced, gas bubbles introduced or formed from the light hydrocarbon liquid components flow through the feedstock 106 and into the gas cap 108.

The term "cracking" as used herein refers to a homogeneous fission reaction of hydrocarbons, wherein larger compounds are broken down into smaller compounds. When hydrogen (H) is present ₂ ) When used, the cracking process is sometimes referred to as hydrocracking. In a preferred embodiment, when cracking is limited to a condensation module as described herein, such cracking eliminates the problems of asphaltenes and the toxic metals associated therewith, as these components remain in the distillation module. This distinguishes "cracking" as discussed from "cracking" in distillation modules.

The term "first transfer channel" refers to any device that allows restricted hydrocarbon vapor and/or condensate to move downstream from the distillation module 100 to the terminal end of the first transfer channel 111 while in communication with each of the condensing modules.

The term "second transfer passage" refers to any device that allows restricted hydrocarbon to move from the first transfer passage 114 or from a condensing module (e.g., 120) where the second transfer passage 128 contains one or more valves 162 that open and close the one or more condensing modules into one or more of the condensing modules (e.g., 122, 124, and 126) to provide control of the flow of hydrocarbon into the one or more of the condensing modules. In one embodiment, an additional valve 160 is provided that opens and closes at the distal end of the second transfer module 128. When open, all or a portion of the hydrocarbons in the second transfer passage 128 may be directed into the third transfer passage 142.

The term "third transfer passage" refers to any device that is compatible with the valve 160 at the end of the second transfer passage 128 and allows for the restricted hydrocarbons to be collected or moved as fuel into the heating element 102 and/or used as an injection source for the feedstock 106 in the distillation module 100.

The term "outlet port" as used herein refers to a separate outlet (e.g., 150) that allows low molecular weight hydrocarbons (e.g., methane and C2-C4 alkanes and alkenes) to be released from the distal portion of the first transfer channel 114 and not recycled into the condensing module.

The term "hydrocarbon" refers to hydrocarbons that are in liquid or gaseous state, unless otherwise specified.

For the purposes of this disclosure and unless otherwise specified, "a" or "an" means "one or more. Sometimes, the claims and disclosure may contain terms such as "plurality", "one or more" or "at least one"; however, the absence of such terms is not intended to mean, and should not be construed to mean, that the plurality/plurality is/are not contemplated.

As used herein, "about" will be understood by one of ordinary skill in the art and will vary to some extent depending on the context in which it is used. If there is a term usage that is not clear to one of ordinary skill in the art, then "about" will mean up to ± 10% variation from the particular term, taking into account the context in which it is used.

All publications, patent applications, issued patents, and other documents mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent application, issued patent, or other document was specifically and individually indicated to be incorporated in its entirety by reference. A definition contained in a text incorporated by reference is excluded if it conflicts with the definition in the present disclosure.

The embodiments illustratively described herein suitably may be practiced in the absence of any element or elements, limitation or limitations, not specifically disclosed herein. Thus, for example, the terms "comprising," "including," "containing," and the like are to be construed broadly and without limitation. Additionally, the terms and expressions which have been employed herein are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. Additionally, the phrase "consisting essentially of 8230 \8230composition of the invention shall be understood to encompass those elements specifically recited and additional elements that do not materially affect the basic and novel characteristics of the claimed invention. The phrase "consisting of 8230; excludes any unspecified elements.

The present invention is not limited to the specific embodiments described herein, which are intended as illustrations of various aspects. It will be apparent to those skilled in the art that many modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. Functionally equivalent compositions, devices, and methods within the scope of the present disclosure, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing description. Such modifications and variations are intended to fall within the scope of the appended claims. The disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. It is to be understood that this disclosure is not limited to particular methods, reagents, compounds, compositions or biological systems, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.

In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any single member or subgroup of members of the Markush group.

As will be understood by one of skill in the art, for any and all purposes, particularly in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be readily identified as being fully described and such that the same range is broken down into at least equal two, three, four, five, ten, etc. shares. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, a middle third, and an upper third, etc. As will also be understood by those of skill in the art, all terms such as "up to," "at least," "greater than," "less than," and the like encompass the referenced number and refer to a range that can be subsequently broken down into subranges as discussed above. Finally, as will be understood by those skilled in the art, a range encompasses each individual member.

Method

In one embodiment, the present invention provides a method comprising:

a) Heating a hydrocarbon feedstock 106 in a distillation module 100 at a first temperature and pressure selected to vaporize at least a portion of the feedstock to produce a distillate vapor having a plurality of fractions, wherein the vapor is collected in the gas cap 108 of distillation module 100, and further wherein the feedstock 106 is optionally sparged while the heating is conducted to reduce the boiling point of the distillate to be recovered;

b) Passing at least a portion of the hydrocarbon vapor through a first transfer passage 114 in communication with a plurality of condensation modules including a first condensation module and a last condensation module, wherein the first transfer passage 114 has a first temperature at an end proximate to the distillation module 100 and a second and lower temperature at an end distal from the last condensation module 111 such that a portion of the hydrocarbon vapor will condense throughout most, if not all, of the first transfer passage 114 and then collect in the condensation modules;

i) From the terminal end of the first transfer channel 111 to one or more of the condensation modules; or

ii) passing from one of the downstream condensing modules to one or more upstream condensing modules;

e) Introducing the hydrocarbons from the second transfer channel into one or more of the condensation modules under conditions in which at least a portion of the hydrocarbons in the modules are cracked; and

In part a), the initial hydrocarbon feedstock is introduced into the distillation module 100 by conventional means. In one embodiment, the feedstock 106 is first warmed to a temperature sufficient to flow into the distillation module 100. This option is preferred if the feedstock 106 is so viscous at ambient temperature that heating is required. Once inside the distillation module 100, the temperature is increased and the pressure adjusted to convert a portion of the liquid hydrocarbon into a distillate of hydrocarbon vapor in the gas cap 108, wherein the vapor, when condensed, includes multiple components or fractions. The particular temperature and pressure used in the distillation module depends on the amount of vaporized fraction desired. Such factors are well known to the skilled person.

In an optional embodiment, a sparging gas or hydrocarbon liquid is introduced into the heated hydrocarbon feedstock 106. Preferably, the sparging gas or hydrocarbon liquid is heated or maintained hot prior to introduction into distillation module 100. The sparging gas or hydrocarbon liquid is preferably introduced under pressure to promote distillation of the hydrocarbon feedstock 106. Without being limited by theory, it is contemplated that the jets facilitate the migration of hydrocarbon bubbles trapped near the heat source to the gas cap 108, thereby reducing the temperature required to perform such migration. In one embodiment, the hydrocarbon liquid injected into the feedstock includes the hydrocarbon liquid provided by the third transfer passage 142, which is maintained in a liquid state at pressure and temperature in the third transfer passage. Without being limited by theory, introducing such a liquid into the feedstock 106 will result in rapid vaporization and the generation of gas bubbles within the feedstock. These bubbles will rise quickly into the gas cap 108, which captures any hydrocarbon bubbles from the feedstock 106 that lack sufficient energy to reach the gas cap 108. Thus, it is envisaged that the addition of such liquid low molecular weight hydrocarbons will reduce the boiling point of the distillable portion of the feedstock.

In a preferred embodiment, the temperature and pressure of the hydrocarbon feedstock 106 and the temperature and pressure of the injection gas or hydrocarbon liquid used for injection are selected to avoid cracking of the feedstock. Cracking at this stage is inefficient because there are many components in the feedstock 106 that are highly resistant to cracking even under severe conditions (e.g., asphaltenes). Thus, these components act as an energy sink, as the injected gas or liquid that collides with these components does not initiate significant cracking. Rather, such collisions absorb energy from the injected components, thereby reducing their energy level and their ability to effectively crack components that may otherwise be subject to cracking.

In one embodiment, a pressure valve 110 is provided that controls the absolute gas pressure within the distillation module. The gas pressure valve may be operated visually, mechanically or automatically. This gas pressure valve 110 operates to maintain a constant pressure level in the gas cap 108.

Parts b) and c) of the method of the invention provide for collecting the condensate into a condensing module (e.g. 122, 124 and 126) and transporting the hydrocarbon vapour downstream in the first transfer channel 114. This allows each condensing module to collect a portion of the condensate.

In part d), hydrocarbons originating from the first transfer passage 114 or the condensing module (e.g., 126) are transported in the second transfer passage 128.

In part e), a portion of the hydrocarbons in the second transfer passage 128 are conveyed to one or more condensing modules (e.g., 122, 124, and 126) to initiate cracking of the liquid condensate in the one or more modules. In one embodiment, the second transfer passage 128 employs a pump or blower 164 that facilitates movement of hydrocarbons through the passage. In one embodiment, the second transfer channel 128 is maintained under conditions in which the hydrocarbon within the channel is in a liquid state. Thus, if the hydrocarbons initially entering the second transfer passage 128 are in a gaseous state, the second transfer passage 128 is preferably maintained under conditions in which these gases are caused to liquefy prior to injection into one or more of the condensation modules. Preferably, the liquefied hydrocarbons are heated and then introduced into the liquid phase of the condensation module under cracking conditions.

In a preferred embodiment, the liquefied hydrocarbons to be injected into the upstream condensation module are preferably injected under pressure through a nozzle mounted to an inlet port on the condensation module. The injected hydrocarbon is preferably introduced into the condensed liquid hydrocarbon found in the condensation module. The temperature and pressure are selected such that at least a portion of the liquid hydrocarbons in the condensing module are cracked.

Without being limited by theory, in a condensation moduleCracking removes the portion of hydrocarbons in the distillation module 100 that would otherwise be adversely subjected to energy sink in the distillation module. Thus, the cracking efficiency is improved because asphaltenes and other energy sink components of the feedstock 106 are not present in the condensing module where cracking occurs. Furthermore, cracking at this stage of the process can be carried out in multiple condensing modules, such that the amount of light ends collected in downstream condensing modules obtainable by the methods described herein is significantly increased. In addition, molecular hydrogen (H) is produced when cracking is carried out under hydrocracking conditions ₂ ) Can act as a desulfurizing agent. This allows the sulfur content of the condensate of the condensing vessel in which hydrocracking is carried out to be reduced. In a preferred embodiment, a sulfur scrubber may be employed in the process to reduce the sulfur content of the hydrocarbons. In another preferred embodiment, the number of condensing modules employed varies from 2 to 10 or more.

In part f), the method continues to be executed until any of the following goals is reached:

increase or maximize the amount of light components (e.g., gasoline and/or diesel) that can be recovered by the processes disclosed herein. This is particularly beneficial when the primary goal is to provide a useable fuel at the initial hydrocarbon source.

Obtaining sufficient lights such that the total API of the modified feedstock increases by at least 5 API units when aggregated with other components of the process (including some or all of the liquid components from each of the condensing modules and distillation modules).

Combining one or more of the light components with individual amounts of starting materials to modify their API so that they can be piped. In this example, the light component acts as an in situ generated diluent so that the initial feedstock that would not otherwise be available for pipeline transportation is now suitable for pipeline transportation.

In one embodiment, the gaseous components that are not converted to liquefied components may be recovered and enriched in low molecular weight hydrocarbons such as methane, ethane, propane, butane, and the like. These components are preferably collected and condensed to be in a liquid state. Suitable uses for such liquids include any of the following:

sold as liquid hydrocarbons.

Conveyed through the third transfer channel 142 to serve as a hydrocarbon energy source for heating the distillation module 100.

Through the third transfer channel 142 for injection into the distillation module 100 in liquid state to initiate injection of the feedstock 106 maintained therein.

In one embodiment, the methods described herein can be performed in a batch or semi-continuous process. In the latter case, additional initial feedstock is added to the distillation module 100 as vaporized feedstock is removed from the module such that the amount of feedstock 106 remains substantially the same over time. The process is semi-continuous because over time there is a build up of non-distillable components, such as the appearance of asphaltenes. This requires stopping the process and removing these components remaining in the module.

In one embodiment, the residue is maintained within the module or other suitable vessel under conditions in which the components in the residue are substantially equilibrated to separate the components from the asphaltene components. In a preferred embodiment, one of the components separated from the asphaltene component is a diesel component which is trapped within asphaltenes.

In one embodiment, the diesel components are separated by reducing the pressure within the distillation vessel 100 to reduce the surface tension between the diesel components and the asphaltene components, thereby vaporizing at least a portion of the diesel components.

In one embodiment, separating the diesel component from the asphaltene component comprises adding a distillate product having an API of 25 or greater to the distillation module.

It is apparent that the methods and apparatus described herein provide significant environmental protection. For example, such methods and apparatus eliminate some or all of the need to provide a dedicated conduit for diluent from a diluent source to a hydrocarbon source. Thus reducing or eliminating the environmental risks associated therewith. In addition, reducing the use of some or all of the diluent also eliminates some or all of the energy required to pump the diluent from the refinery to the feedstock source and then again separate the diluent from the feedstock when returned to the refinery. Still further, as the cracking is carried out in the condensing module, the energy absorbing uncracked components found in the distillation module (energy sink) are removed and the cracking is more efficient. It is envisaged to do so to provide reduced energy usage. Finally, methane and other low molecular weight hydrocarbons are used as collected above and avoid the release of these greenhouse gases into the atmosphere. In this regard, it is noted that methane and other low molecular weight hydrocarbons are well known greenhouse gases.

Device

The apparatus of the various embodiments disclosed herein provides means for increasing the amount of light ends that can be recovered from a hydrocarbon feedstock (e.g., a heavy feedstock). Such a device is formed of a plurality of modules. Each module defines a reservoir configured to maintain the hydrocarbons in a liquid and/or gaseous state. In various embodiments, the modules are connected in series by a first transfer channel that provides for the transfer of gas from one module to another or from one module to an outlet port.

In one aspect, the present invention provides an apparatus for increasing the amount of light components that can be recovered from a hydrocarbon feedstock while separating the feedstock into components. The apparatus comprises: a distillation module 100; an inlet configured to deliver a hydrocarbon feedstock 104 to the distillation module 100 and two or more serially connected condensation modules. In a preferred embodiment, the condensing modules (e.g., 122, 124, and 126) are designed to maintain a specific temperature range of the gaseous components maintained therein. This may be accomplished by internal or external heating elements or other means known in the art.

In some embodiments, the apparatus for separating the hydrocarbon feedstock 106 may further comprise a fractionation column (not shown), such as, for example, a metal belt, a metal coil, a metal mesh, a woven metal or composite fiber, or other suitable material suspended or disposed within the first transfer passage 114 or in one or more of the condensing modules. Such a column may have a surface temperature that is lower than the ambient temperature of the module or conduit and thus promotes condensation on the column.

Other components may also be included in the apparatus. For example, an accumulator or piping system may connect the inlet of the distillation module to a source of liquid hydrocarbon oil feedstock. The accumulator or piping system may be connected to any of the modules, such as 144, 146 and 148, to collect the hydrocarbon fraction products (i.e., components) condensed within the modules.

FIG. 1 schematically depicts one embodiment of an apparatus or system for separating hydrocarbon components. In the depicted embodiment, distillation module 100 includes a heating element 102, an air inlet valve 104, feedstock 106, an air cap 108, a pressure valve 110, and optionally an inlet valve 112 that mates with a nozzle 113 (shown in fig. 3).

Distillation module 100 is formed from one or more container walls defining an internal reservoir. Vaporization is performed within the internal reservoir. Specifically, a hydrocarbon feedstock is introduced into the distillation module 100 through a feedstock inlet 104. The feedstock may, for example, come from a connected storage vessel and/or a direct source of hydrocarbon oil feedstock. In one non-limiting embodiment, the hydrocarbon oil feedstock is crude oil. When filled with a sufficient volume of hydrocarbon oil feedstock, the distillation module 100 is heated by the heating element 102 at a temperature T1 or to a temperature T1 to produce a vapor V1 from the feedstock. In various embodiments, the temperature T1 is high enough to vaporize substantially all of the desired components found in the feedstock. In various embodiments, the temperature T1 is greater than the boiling point of each desired component at the pressure used inside the distillation module.

In some embodiments, the hydrocarbon oil feedstock within the distillation module 100 may be sprayed in order to increase the rate and/or decrease the temperature of the vaporization process within the distillation module 100. The ejection may be from a single port or from multiple ports in any alignment. In the illustrated embodiment, a single port 112 is illustrated and employs a gas or liquid to inject the feedstock 106 to be distilled.

The pressure valve 110 maintains the gas pressure within the distillation module at a preselected value selected to maximize distillation at a minimum energy cost. In some embodiments, the pressure may be a subatmospheric pressure, and in other embodiments, the pressure may be a plurality of atmospheres. When the gas pressure exceeds a preselected value, the valve 110 opens and the gas within the gas cap 108 flows into the transfer passage 114. The position of the pressure valve 110 and the transfer channel 114 in the distillation module is selected with respect to the portion of gas to be released. In one embodiment, the pressure valve 110 may be positioned directly above the liquid feed 106 to ensure that the gas flowing into the first transfer channel 114 contains a mixture of higher and lower molecular weight components. Alternatively, the gas cap 108 may be mixed using any suitable means (including fans, sparge gases, etc.) to homogenize the hydrocarbon vapor therein.

The first transfer passage 114 is fixed to the valve 110 in the distillation module 100, and the gas flowing in is at the first temperature T1. The first delivery passage 114 allows gas to flow downstream to the distal point 111 having a second temperature T2, where T2 is less than T1. As the gases cool during traversal from the proximal end of the first transfer channel 114 to the distillation end 111, condensate forms and is directed by a plurality of

drains

116, 118, and 120, each associated with a

separate condensing module

122, 124, and 126, respectively. The design of these drains may vary significantly from a single port to multiple ports 140 (each indicated by a single dashed line) connected to a single drain tube 116 as shown in fig. 2.

One or more of the condensing

modules

122, 124, and 126 contains an inlet port 130 for introducing hydrocarbons into the condensate contained therein. The positioning of the inlet port 130 is arbitrarily shown at the bottom of the condensing module, but may be positioned elsewhere as desired. The introduced hydrocarbon flows out from the second transfer passage 128. In the preferred embodiment, the input device 132 mates with the outlet port 130 of the second delivery channel (FIG. 4). Each of the condensing

modules

122, 124 and 126 contains a

condensate drain

144, 146 and 148, respectively, that allows condensate to collect from each module. In one optional embodiment illustrated in fig. 1, the condensate drain 148 may feed into the second transfer channel 128 to provide additional liquid hydrocarbon for cracking condensate in any condensing module. As the process continues, the API of the condensate in any or all of the condensing modules increases as the cracking proceeds. In one embodiment, the process continues until liquid hydrocarbons have been obtained with a sufficiently high API, such that these hydrocarbons can be blended with a low API feed to increase the API of the feed by about 5 API units or more.

In the depicted embodiment, the end portions of the terminal drain 120 define the distal end portion 111 of the first delivery channel 114 and the proximal end portion of the second delivery channel 128. The differences between these two channels include, but are not limited to, the following:

the first transfer channel 114 contains

drains

116, 118 and 120 that allow the condensate to collect in the

condensation modules

122, 124 and 126, respectively, whereas the second transfer channel does not.

The second transfer channel 128 comprises an outlet port 132 (fig. 4), preferably found with each of the

condensation modules

122, 124 and 126, which is fixed or matched to the inlet port 130 on these condensation modules. Preferably, the inlet port 130 is positioned near the bottom of the condensing module to facilitate the injection of hydrocarbons into the condensate.

The second transfer passage 128 terminates in a valve or closure 160. When the second transfer passage 128 terminates in the valve 160, the valve opens to the third transfer passage 142, which feeds the hydrocarbon to the heating element 102 and/or the hydrocarbon feedstock 106 introduced into the distillation module 100. In the embodiment shown in fig. 1, the third transfer passage 142 is used to pass hydrocarbons remaining after circulation through the first transfer passage 114 and the second transfer passage 128 as an injection liquid or gas for introduction into the distillation module.

It should be understood that the second transfer passage 128 may begin at one of the downstream condensing modules, such as the condensing module 126. As illustrated in fig. 5, hydrocarbons (liquid or vapor or both) may be removed from the condensation module 126 by feeding the outlet 148 into the second transfer passage 128 or by activating the second transfer passage 128 in the gas directly above the condensate in the condensation module 126. In fig. 5, two options are depicted, but it should be understood that only 1 of these 2 options is needed. Once the hydrocarbons are located inside the second transfer passage 128, they are preferably maintained in the liquid state or converted to the liquid state by appropriate temperature and pressure. The hydrocarbons are then recycled for injection into one or more of the condensing

modules

122, 124, and/or 126, or alternatively, fed into the third transfer passage 142 as described above.

Although not shown, the second transfer passage 128 and the third transfer passage 142 each optionally contain a pump or blower, and optionally contain a heating device to convert the hydrocarbons to their liquid state at a suitable pressure and temperature. These liquid hydrocarbons, which are preferably heated, are introduced under cracking conditions into one or more of the condensing

modules

122, 124, and/or 126, or used as fuel for the heating element 102 or introduced as an injected liquid into the liquid hydrocarbons 106.

Fig. 4 shows that the matching means 130 on the condensation vessel matches with the corresponding means 132 in the second transfer channel to allow introduction of the hydrocarbon connection in the second transfer channel 128 into the condensate 150 of the condensation module. The matching device 130 is preferably capable of injecting hydrocarbons into the liquid condensate 150 at high pressure and temperature. Each matching device 130 attached to each condensing

module

122, 124 and 126 has an open and closed position that operates independently of each other so that cracking can be performed in one, two or three condensing modules simultaneously or sequentially or only in a subset thereof.

Fig. 5 shows an alternative design for the apparatus and method of the present invention. In fig. 5, the first transfer channel 114 terminates in a drain 120 and an outlet port 150. The outlet port 150 is located at the end of the first transfer channel 114 and is designed to allow low molecular weight hydrocarbons to exit the channel. Preferably, these low molecular weight hydrocarbons are captured and liquefied for use as an energy source.

Claims

1. An apparatus, comprising: a distillation module adapted to distill a hydrocarbon feedstock into a liquid component and a gas component; a first transfer channel; and a plurality of condensing modules arranged sequentially along the first conveying channel to define an upstream condensing module and a downstream condensing module;

a) A heating element for heating the feedstock in the distillation module,

b) A second transfer passage positioned to transfer hydrocarbons

i) Moving from the terminal end of the first transport path to one or more of the condensing modules;

d) An introduction device connected to the second transfer passage to enable introduction of the hydrocarbons conveyed in the second transfer passage into one or more of the one or more condensation modules under conditions to crack at least a portion of the hydrocarbon condensate in the one or more modules; and

2. The apparatus of claim 1, wherein the second transfer channel is configured to convert or maintain the hydrocarbons contained therein in a liquid state.

3. The apparatus of claim 2, wherein the second transfer channel is configured to introduce the hydrocarbons into the hydrocarbon liquid condensate of one or more of the one or more condensation modules.

4. The apparatus of claim 3, wherein the introducing means is a nozzle that allows for injection of hydrocarbon liquid from the second transfer channel into the condensate of the condensing module.

5. The apparatus of claim 2, wherein the liquid in the second transfer channel is heated.

6. The device of claim 5, wherein the liquid is heated by a heating element.

7. The device of claim 6, wherein the heating element is located outside of the second transfer channel.

8. The apparatus of claim 7, wherein the heating element is selected from the group consisting of a microwave oven, an electric heater, a heat exchanger, or exposing the transfer channel to hot exhaust gases.

9. The apparatus of claim 6, wherein the heating element is located inside the transfer channel.

10. The apparatus of claim 1, wherein the second transfer channel is configured to convert or maintain the hydrocarbons contained therein in a gaseous state.

11. The apparatus of claim 10, wherein a terminal end of the second transfer channel is connected to a third transfer channel through a valve, wherein the third transfer channel is designed to provide fuel to the heating element and/or to provide hydrocarbons to inject the feedstock in the distillation module.

12. The apparatus of claim 1, wherein the introducing means is a nozzle that allows hydrocarbon gas to be injected from the second transfer channel into the condensate of the condensing module.

13. The apparatus of claim 10, wherein the gas in the second transfer channel is heated.

14. The apparatus of claim 13, wherein the gas is heated by a heating element.

15. The apparatus of claim 14, wherein the heating element is located outside of the second transfer channel.

16. The apparatus of claim 15, wherein the heating element is selected from the group consisting of a microwave oven, an electric heater, a heat exchanger, or exposing the second transfer channel to hot exhaust gases.

17. The apparatus of claim 14, wherein the heating element is located inside the second transfer channel.

18. The apparatus of claim 1, wherein the apparatus further comprises a pressure valve located between a gas cap of the distillation module and the first condensation module.

19. The apparatus of claim 18, wherein the pressure valve controls absolute gas pressure within the distillation module.

20. The apparatus of claim 1 or 18, wherein the apparatus further comprises a gas outlet port in the first transfer channel.

21. A method, comprising:

a) Heating a hydrocarbon feedstock in a distillation module at a first temperature and pressure selected to vaporize at least a portion of the hydrocarbon feedstock to produce a distillate vapor having a plurality of fractions in a gas cap, wherein the vapor is collected in the gas cap of the distillation module, and further wherein the feedstock is optionally sparged while the heating is conducted to reduce the boiling point of the distillate to be recovered;

b) Passing at least a portion of the hydrocarbon vapor through a first transfer channel in communication with a plurality of condensation modules including a first condensation module and a last condensation module, wherein the first transfer channel has a first temperature at an end proximate to the distillation module and a second and lower temperature at an end distal from the last condensation module such that a portion of the hydrocarbon vapor will condense throughout a majority of the first transfer channel and then collect in the condensation module;

d) Producing a hydrocarbon stream through a second transfer channel, wherein the second transfer channel is capable of transferring hydrocarbons

i) Conveying from the terminal end of the first conveying channel to one or more of the condensing modules;

e) Introducing the hydrocarbons from the second transport channel into one or more of the condensation modules under conditions in which at least a portion of the hydrocarbon condensate in the condensation modules is cracked; and

f) Steps e) to f) are continued until the desired amount of light liquid hydrocarbon fraction is recovered.

22. The method of claim 21, wherein the conditions maintained in the distillation module are non-cracking conditions.

23. The method of claim 21, wherein the method provides for adding additional initial feedstock to the distillation module as vaporized feedstock is removed from the distillation module.

24. The method of claim 21, wherein after termination of the process, the residue remaining in the distillation module is maintained within the module or other suitable vessel under conditions in which the components within the residue are equilibrated to separate components that were captured in the asphaltene component prior thereto.

25. The method of claim 24, wherein one of the components separated from the asphaltene component is a diesel component.

26. The method of claim 25, wherein the diesel component is separated by reducing the pressure within the reaction vessel to reduce the surface tension between the diesel component and the asphaltene component, thereby vaporizing at least a portion of the diesel component.

27. The method of claim 26, wherein the separation of the diesel component from the asphaltene component is facilitated by adding a distillate product having an API of 30 or greater to the distillation module.